Today with the trend to increase production speeds above 1000 fpm, there is a need to improve the coating application methods. Primer applications for the extrusion coating process consisted of Direct Forward Gravure, Direct Reverse Gravure, Offset Gravure and Smooth Roll Transfer coaters. At the higher speeds, the ability to apply low coat weights by the existing coaters has become greatly limited. To produce the desired results at the increased operating speeds, new coater variations must be employed. The primary goal is to determine the operating parameters and required modifications for each type of coater to achieve low coat weights above 1000 fpm. Yesterdays conventional coaters applying higher coat weights at lower operating speeds were accepted. Today the price competition is driving the market to lower the operating cost. This requires the manufacturer to increase speed and lower coat weights to sustain their position in the market. Two issues;

1) How do you lower the coat weight? 2) What effects does raising the speed create?

Lowering coat weight can be achieved by updating the coating equipment with new state of the art technology. Gravure coaters have progressed with the addition of new pumps, better engraving technology, enclosed applicators, and pressurized applicators. Other factors include correct plumbing, locating the applicator in the correct position, rubber Shore A and rubber compound. The gravure coater consists of a steel roll with a pattern engraved into the surface, an applicator doctoring system and a rubber backup roll. The Offset Gravure coater consists of the same with the addition of a chrome backup roll and the rubber roll becomes the transfer roll. The gravure roll is constructed from a steel shell and roll journals. Advances to the gravure roll technology consist of new roll design that can be cooled by filling the center with cooling water, it can be constructed with a double shell to improve cooling

Lee A. OstnessProduct Manager Coating & Drying Systems Davis-Standard, LLC

uniformity, or it can be constructed with spiral flutes to achieve ∓3℉ ∆T across the roll face. The construction of the roll tolerances has improved to produce a straight roll with consistent TIR. To achieve a more consistent release of the coating from the gravure pattern, first build up the surface with copper and then engrave the pattern into the copper then flash chrome plate. This will give a very uniform pattern verses engraving the steel surface. Another option would be to coat the surface with a ceramic buildup and laser engrave the pattern into the ceramic coating. This will lengthen the life of the gravure roll more than 3X. The ceramic gravures could be a little too course for priming some sensitive films, foils, or printed surfaces. The rubber roll has improved with new rubber compounds, more consistent hardness cross web, and better mechanical durability. The sleeve system has provided quicker changeover between web width changes and allows the converter to change rubber compound hardness for multiple product runs. Make sure you order the correct rubber compound for your application. Smooth Roll priming the rubber should repel the solution coating while in offset gravure coating the rubber should wet out the entire surface evenly. For Direct Gravure coating the rubber does not see the solution coating but should be selected to with stand friction, heat, swelling and the web surface contaminates. The applicators for gravure coating have gone from an open pan with a wiping doctor system to an enclosed plowing doctoring system. The open pan was fine for water base coatings at low speeds. With high line speeds the roll would throw the coating out of the pan, the enclosed applicator contains all the coating. The enclosed system incorporates the plowing angle for the doctoring system witch will stay in contact with the gravure surface at all line speeds. The wiping doctor system could lift off the roll surface due to hydraulic forces from the coating at higher line speeds. The enclosed applicators could cause some foaming issues with the primer solution if the flow rate is too low. The flow of coating through the enclosed system should be designed for a minimum of 3 times the amount to be applied to the web. This means if you are applying 1 gpm to the web you should be supplying 3 gpm to the applicator with 2 gpm recirculated back to the supply tank. The plumbing of the return lines should be done to cause the least amount of resistance. Each return line should be independent of the others using the largest diameter and shortest run as possible avoiding dips which will cause a plug flow. The atmospheric enclosed applicator should be set up at either

3’oclock or 9 o’clock positions. The side of the roll will depend on roll direction. The top doctor blade should be the doctoring blade to allow smooth flow patterns inside the head. If the

bottom blade is used for doctoring it could cause turbulent flow = foam.

The Direct Forward and Reverse Gravure coaters are ok for 1000 to 1500 fpm But above the 1000 fpm either a offset gravure coater should be used or an pressurized applicator be installed. The speed of the gravure roll will increase the amount of turbulence in the applicator so the slower the roll speed the better the application. With Offset Gravure the gravure roll is typically operated between 25 to 30% of the web speed. The pressurized gravure head is designed to apply coating to the gravure roll at high speeds and to reduce the amount of foaming of the primer solution. The

preferred design will have small flow channels, recirculation, and the ability to pressurize. If designed correctly the density of the solution coating will be the same after it exits the applicator as it is when it entered. This is very important tool for primers that foam very easily.

The Smooth Roll coaters operate on the hydraulic force principle. By

determining the correct operating conditions, nip, speed, shore hardness of the coater the coat weight can be controlled. But at higher operating speed the hydraulic forces increase so harder rubber compounds are necessary. The need to crown the rubber rolls may also be required due to excessive hydraulic deflection. With higher line speeds the roll speed

increases requiring the coating pan will need to be designed for higher flow rates and coating slinging. Sling guards are required for control of the coating being slung from the end of the coating rolls. For line speeds above 1000 fpm a three roll smooth coater should be used to reduce the speed of the rolls in the coating pan. The coating supply pumps should be selected for the correct application. For an open pan system, a diaphragm pump may be used only if the pan is designed

correctly to eliminate the pulse created by the diaphragm pump. The centrifugal pump may be used for the open pan systems and for the enclosed applicators. They must be sized large enough to allow the correct flow rate taking into

consideration the distance from the coater head and the height up to the coater head. For higher flow rates and for the pressurized systems a positive displacement and low shear should be selected.

GPM Density In

Density Out

0.63 9.2 7.770.99 8.92 8.31.44 8.91 8.51.98 8.95 8.632.44 8.65 8.64

To lower the coat weight applied and increase line speed for the various coater setups are as follows: Direct Forward Gravure • Speeds up to 1000 fpm open pan system,

1. choose the correct gravure pattern 2. update your pan design 3. invert the doctor system from wiping to plowing

• Speeds 1000 fpm to 1500 fpm 1. choose the correct gravure pattern 2. replace the pan with an enclosed applicator system 3. if enclosed system already exist – make sure its on the correct side of the

gravure roll 4. select the correct pump 5. plump the coating supply system correctly

• Speeds 1500 fpm and up 1. choose the correct gravure pattern 2. Replace the open pan or enclosed applicator with a pressurized applicator 3. upgrade the pump to handle the pressure requirement 4. replace the coater with Offset Gravure

Direct Reverse Gravure • Speeds up to 1000 fpm open pan system,

1. choose the correct gravure pattern 2. update your pan design 3. invert the doctor system from wiping to plowing

• Speeds 1000 fpm to 1500 fpm 1. choose the correct gravure pattern 2. replace the pan with an enclosed applicator system 3. if enclosed system already exist – make sure its on the correct side of the

gravure roll 4. select the correct pump 5. plump the coating supply system correctly

• Speeds 1500 fpm and up 1. choose the correct gravure pattern 2. Replace the open pan or enclosed applicator with a pressurized applicator 3. upgrade the pump to handle the pressure requirement 4. Replace the coater with Offset Gravure

Offset Gravure • Speeds up to 1000 fpm, open pan system

1. choose the correct gravure pattern 2. update your pan design 3. invert the doctor system from wiping to plowing 4. reduce the speed of the gravure roll to 20 – 30% of line speed

• Speeds 1000 fpm to 1500 fpm 1. choose the correct gravure pattern 2. replace the pan with an enclosed applicator system 3. if enclosed system already exist – make sure its on the correct side of the

gravure roll 4. select the correct pump 5. plump the coating supply system correctly 6. reduce the speed of the gravure roll to 20 – 30% of line speed

• Speeds 1500 fpm and up 1. choose the correct gravure pattern 2. Replace the open pan or enclosed applicator with a pressurized applicator 3. upgrade the pump to handle the pressure requirement 4. Replace the coater with Offset Gravure 5. reduce the speed of the gravure roll to 20 – 30% of line speed

Smooth Roll (2 Roll System) • Speeds up to 1000 fpm

1. use the correct pressure setting 2. determine the correct roll speed 3. update the rubber roll 4. update your pan design 5. upgrade the sling guard

• Speeds from 1000 fpm to 1500 fpm 1. use the correct pressure setting 2. determine the correct roll speed 3. increase the rubber hardness from 60 to 80 Shore A 4. update your pan design 5. upgrade the sling guard

• Speeds from 1500 fpm and up 1. replace the 2 roll system with the 3 roll system 2. use the correct pressure setting 3. determine the correct roll speeds 4. increase the rubber hardness from 60 to 80 Shore A 5. update your pan design 6. upgrade the sling guard

Smooth Roll (3 roll system) Proprietary set up – see me

2007 PLACE Conference

September 16-20

St Louis, MO

High Speed PrimingHow To Lower Coat Weight & Raise Line Speed

Presented by:Lee A. OstnessProduct Manager Coating & Drying SystemsBlack Clawson Converting Machinery

PRIMER COATERS

DIRECT GRAVURE REVERSE GRAVURE OFFSET GRAVURE SMOOTH ROLL

Methodology of Application

Gravure Coater Smooth Roll Coater

Gravure Style CoatersIncrease Speed – Lower Coat Weight

• Gravure pattern• Doctor system• Applicator design• Air entrainment in the Coating• Pump• Plumbing

Gravure Engraved Patterns

Volume “BCM”

Billion Cubic Microns

The formula is based on ink technology. Many oftoday's coatings are ofan unique composition.Use this formula for abetter understanding ofhow the cell volumes areachieved. Coat weights may vary when different coatings are applied with the same cell volume.

formula from Consolidated Engravers

CHARTS REFERENCED FROM:PAMARCO, INC.

200 0.0008 2.6 0.21 0.26 0.32 0.47 0.70 200 0.0012 5.7 0.22 0.32 0.48 0.71 1.05 1.31 120 0.0022 18.0 0.64 0.95 1.40 2.07 3.07 3.80 ARC INDUSTRIES, INC.180 0.0009 3.2 0.23 0.29 0.36 0.53 0.79 190 0.0015 7.5 0.27 0.40 0.60 0.89 1.31 1.63 110 0.0025 20.3 0.73 1.08 1.60 2.37 3.51 4.35 AMERICAN ENGRAVING AND MACHINE CO.165 0.0010 3.4 0.26 0.32 0.40 0.59 0.88 180 0.0018 9.4 0.33 0.48 0.72 1.07 1.58 1.96 95 0.0032 26.2 0.94 1.39 2.05 3.03 4.49 5.57 MODERN ENGRAVING AND MACHINE CO.150 0.0020 7.5 0.51 0.64 0.80 1.18 1.75 165 0.0022 10.9 0.30 0.49 0.80 1.30 1.93 2.39 90 0.0035 28.8 1.03 1.52 2.25 3.33 4.93 6.11142 0.0022 8.2 0.56 0.70 0.88 1.30 1.92 150 0.0025 13.3 0.46 0.68 1.00 1.48 2.19 2.72 84 0.0039 32.3 1.14 1.69 2.50 3.70 5.48 6.79132 0.0025 9.7 0.64 0.80 1.00 1.48 2.19 140 0.0028 15.0 0.51 0.76 1.12 1.66 2.45 3.05 79 0.0040 32.7 1.18 1.75 2.58 3.81 5.64 6.99120 0.0030 11.0 0.77 0.96 1.20 1.78 2.63 130 0.0030 16.0 0.55 0.81 1.20 1.78 2.63 3.26 72 0.0045 36.8 1.32 1.95 2.88 4.26 6.30 7.81116 0.0032 11.9 0.81 1.02 1.28 1.89 2.80 120 0.0032 17.2 0.59 0.87 1.28 1.89 2.80 3.48 64 0.0051 41.8 1.50 2.22 3.28 4.85 7.18 8.89108 0.0033 12.2 0.85 1.06 1.32 1.95 2.89 110 0.0039 21.4 0.71 1.05 1.56 2.31 3.42 4.24 59 0.0055 45.0 1.61 2.39 3.53 5.22 7.73 9.57100 0.0035 13.9 1.03 1.20 1.40 2.07 3.07 96 0.0044 26.3 0.80 1.19 1.76 2.61 3.85 4.79 54 0.0060 49.0 1.76 2.60 3.85 5.70 8.44 10.4690 0.0038 16.0 0.98 1.22 1.52 2.25 3.33 85 0.0049 30.0 0.90 1.32 1.96 2.90 4.29 5.33 50 0.0065 53.3 1.91 2.83 4.18 6.18 9.15 11.3480 0.0040 17.3 1.02 1.28 1.60 2.37 3.50 75 0.0054 32.0 0.98 1.46 2.16 3.20 4.73 5.88 45 0.0073 59.6 2.14 3.17 4.68 6.92 10.25 12.7070 0.0045 18.0 1.15 1.44 1.80 2.66 3.94 65 0.0060 35.4 1.10 1.62 2.40 3.55 5.26 6.53 42 0.0075 61.5 2.19 3.25 4.80 7.10 10.52 13.0465 0.0050 20.4 1.28 1.60 2.00 2.96 4.38 55 0.0065 40.4 1.19 1.76 2.60 3.85 5.69 7.07 36 0.0090 73.3 2.64 3.91 5.78 8.55 12.66 15.6860 0.0058 24.4 1.49 1.86 2.32 3.43 5.08 45 0.0068 44.5 1.24 1.84 2.72 4.03 5.96 7.40 35 0.0093 76.0 2.80 4.09 5.98 8.74 13.10 16.2355 0.0062 26.6 1.58 1.98 2.48 3.67 5.43 35 0.0070 46.6 1.28 1.89 2.80 4.14 6.13 7.62 33 0.0096 78.2 2.81 4.16 6.15 9.10 13.48 16.7050 0.0076 33.7 1.94 2.42 3.02 4.47 6.61 30 0.0090 58.7 1.64 2.43 3.60 5.33 7.88 9.79 28 0.0110 90.0 3.22 4.77 7.05 10.43 15.45 19.1545 0.0090 41.0 2.30 2.88 3.60 5.33 7.88 25 0.0120 81.0 2.19 3.25 4.80 7.10 10.51 13.06 26 0.0130 106.5 3.81 5.63 8.33 12.32 18.25 22.6140 0.0104 48.0 2.67 3.33 4.16 6.15 9.11 16 0.0170 117.0 3.11 4.60 6.80 10.06 14.89 16.50 24 0.0140 115.0 4.09 6.05 8.95 13.24 19.62 24.31

DIRECT FORWARD GRAVURE

0.0008 2.6 0.17 0.21 0.26 0.38 0.56 0.0012 5.7 0.18 0.26 0.38 0.57 0.84 1.05 0.0012 5.7 0.20 0.30 0.44 0.65 0.97 1.21 0.0022 18.0 0.51 0.76 1.12 1.66 2.460.0009 3.2 0.19 0.23 0.29 0.42 0.63 0.0015 7.5 0.22 0.32 0.48 0.71 1.05 1.30 0.0015 7.5 0.25 0.37 0.55 0.82 1.21 1.50 0.0025 20.3 0.58 0.86 1.28 1.90 2.810.0010 3.4 0.20 0.26 0.32 0.47 0.70 0.0018 9.4 0.26 0.39 0.58 0.86 1.26 1.57 0.0018 9.4 0.30 0.45 0.66 0.98 1.45 1.80 0.0032 26.2 0.75 1.11 1.64 2.42 3.590.0020 7.5 0.41 0.51 0.64 0.94 1.40 0.0022 10.9 0.24 0.39 0.64 1.04 1.54 1.91 0.0022 10.9 0.28 0.45 0.74 1.20 1.78 2.20 0.0035 28.8 0.82 1.22 1.80 2.66 3.940.0022 8.2 0.45 0.56 0.70 1.04 1.54 0.0025 13.3 0.37 0.54 0.80 1.18 1.75 2.18 0.0025 13.3 0.42 0.62 0.92 1.36 2.01 2.50 0.0039 32.3 0.91 1.35 2.00 2.96 4.380.0025 9.7 0.51 0.64 0.80 1.18 1.75 0.0028 15.0 0.41 0.60 0.90 1.33 1.96 2.44 0.0028 15.0 0.47 0.70 1.03 1.53 2.25 2.81 0.0040 32.7 0.95 1.40 2.06 3.05 4.510.0030 11.0 0.61 0.77 0.96 1.42 2.10 0.0030 16.0 0.44 0.65 0.96 1.42 2.10 2.61 0.0030 16.0 0.50 0.74 1.10 1.64 2.42 3.00 0.0045 36.8 1.05 1.56 2.30 3.41 5.040.0032 11.9 0.65 0.82 1.02 1.51 2.24 0.0032 17.2 0.47 0.69 1.02 1.51 2.24 2.78 0.0032 17.2 0.54 0.80 1.18 1.74 2.58 3.20 0.0051 41.8 1.20 1.77 2.62 3.88 5.740.0033 12.2 0.68 0.85 1.06 1.56 2.31 0.0039 21.4 0.57 0.84 1.25 1.85 2.74 3.39 0.0039 21.4 0.65 0.97 1.44 2.13 3.15 3.90 0.0055 45.0 1.29 1.91 2.82 4.18 6.180.0035 13.9 0.82 0.96 1.12 1.66 2.46 0.0044 26.3 0.64 0.95 1.41 2.09 3.08 3.83 0.0044 26.3 0.74 1.09 1.62 2.40 3.54 4.41 0.0060 49.0 1.41 2.08 3.08 4.56 6.750.0038 16.0 0.78 0.98 1.22 1.80 2.66 0.0049 30.0 0.72 1.06 1.57 2.32 3.43 4.26 0.0049 30.0 0.82 1.22 1.80 2.67 3.95 4.90 0.0065 53.3 1.53 2.26 3.34 4.94 7.320.0040 17.3 0.82 1.02 1.28 1.90 2.80 0.0054 32.0 0.79 1.17 1.73 2.56 3.78 4.70 0.0054 32.0 0.91 1.34 1.99 2.94 4.35 5.41 0.0073 59.6 1.71 2.53 3.74 5.54 8.200.0045 18.0 0.92 1.15 1.44 2.13 3.15 0.0060 35.4 0.88 1.30 1.92 2.84 4.21 5.22 0.0060 35.4 1.01 1.49 2.21 3.27 4.84 6.01 0.0075 61.5 1.76 2.60 3.84 5.68 8.420.0050 20.4 1.02 1.28 1.60 2.37 3.50 0.0065 40.4 0.95 1.40 2.08 3.08 4.55 5.66 0.0065 40.4 1.09 1.62 2.39 3.54 5.23 6.50 0.0090 73.3 2.11 3.13 4.62 6.84 10.130.0058 24.4 1.19 1.49 1.86 2.74 4.06 0.0068 44.5 0.99 1.47 2.18 3.22 4.77 5.92 0.0068 44.5 1.14 1.69 2.50 3.71 5.48 6.81 0.0093 76.0 2.24 3.27 4.78 6.99 10.480.0062 26.6 1.26 1.58 1.98 2.94 4.34 0.0070 46.6 1.02 1.51 2.24 3.31 4.90 6.10 0.0070 46.6 1.18 1.74 2.58 3.81 5.64 7.01 0.0096 78.2 2.25 3.33 4.92 7.28 10.780.0076 33.7 1.55 1.94 2.42 3.58 5.29 0.0090 58.7 1.31 1.95 2.88 4.26 6.30 7.83 0.0090 58.7 1.51 2.24 3.31 4.90 7.25 9.01 0.0110 90.0 2.58 3.81 5.64 8.34 12.360.0090 41.0 1.84 2.30 2.88 4.26 6.30 0.0120 81.0 1.76 2.60 3.84 5.68 8.41 10.45 0.0120 81.0 2.02 2.99 4.42 6.53 9.67 12.02 0.0130 106.5 3.05 4.51 6.66 9.86 14.600.0104 48.0 2.13 2.66 3.33 4.92 7.29 0.0170 117.0 2.49 3.68 5.44 8.05 11.91 13.20 0.0170 117.0 2.86 4.23 6.26 9.26 13.70 15.18 0.0140 115.0 3.27 4.84 7.16 10.59 15.70

DIRECT REVERSE GRAVURE

0.0008 2.6 0.14 0.17 0.20 0.30 0.45 0.0012 5.7 0.14 0.21 0.31 0.45 0.67 0.84 0.0012 5.7 0.16 0.24 0.35 0.52 0.77 0.96 0.0022 18.0 0.41 0.61 0.90 1.32 1.960.0009 3.2 0.15 0.19 0.23 0.34 0.51 0.0015 7.5 0.17 0.26 0.38 0.57 0.84 1.04 0.0015 7.5 0.20 0.30 0.44 0.66 0.96 1.20 0.0025 20.3 0.47 0.69 1.02 1.52 2.250.0010 3.4 0.16 0.20 0.26 0.38 0.56 0.0018 9.4 0.21 0.31 0.46 0.68 1.01 1.25 0.0018 9.4 0.24 0.36 0.53 0.79 1.16 1.44 0.0032 26.2 0.60 0.89 1.31 1.94 2.870.0020 7.5 0.33 0.41 0.51 0.76 1.12 0.0022 10.9 0.19 0.32 0.51 0.83 1.24 1.53 0.0022 10.9 0.22 0.36 0.59 0.96 1.42 1.76 0.0035 28.8 0.66 0.97 1.44 2.13 3.160.0022 8.2 0.36 0.45 0.56 0.83 1.23 0.0025 13.3 0.29 0.43 0.64 0.95 1.40 1.74 0.0025 13.3 0.34 0.50 0.74 1.09 1.61 2.00 0.0039 32.3 0.73 1.08 1.60 2.37 3.510.0025 9.7 0.41 0.51 0.64 0.95 1.40 0.0028 15.0 0.33 0.48 0.72 1.06 1.57 1.95 0.0028 15.0 0.38 0.56 0.82 1.22 1.80 2.24 0.0040 32.7 0.76 1.12 1.65 2.44 3.610.0030 11.0 0.49 0.61 0.77 1.14 1.68 0.0030 16.0 0.35 0.52 0.77 1.14 1.68 2.09 0.0030 16.0 0.40 0.60 0.88 1.31 1.94 2.40 0.0045 36.8 0.84 1.25 1.84 2.73 4.030.0032 11.9 0.52 0.65 0.82 1.21 1.79 0.0032 17.2 0.38 0.55 0.82 1.21 1.79 2.23 0.0032 17.2 0.43 0.64 0.94 1.39 2.06 2.56 0.0051 41.8 0.96 1.42 2.10 3.10 4.600.0033 12.2 0.54 0.68 0.84 1.25 1.85 0.0039 21.4 0.46 0.67 1.00 1.48 2.19 2.71 0.0039 21.4 0.52 0.78 1.15 1.70 2.52 3.12 0.0055 45.0 1.03 1.53 2.26 3.34 4.950.0035 13.9 0.66 0.77 0.90 1.32 1.96 0.0044 26.3 0.51 0.76 1.13 1.67 2.46 3.07 0.0044 26.3 0.59 0.87 1.30 1.92 2.83 3.53 0.0060 49.0 1.12 1.66 2.46 3.65 5.400.0038 16.0 0.63 0.78 0.97 1.44 2.13 0.0049 30.0 0.57 0.85 1.25 1.86 2.75 3.41 0.0049 30.0 0.66 0.97 1.44 2.13 3.16 3.92 0.0065 53.3 1.22 1.81 2.68 3.96 5.860.0040 17.3 0.66 0.82 1.02 1.52 2.24 0.0054 32.0 0.63 0.93 1.38 2.05 3.03 3.76 0.0054 32.0 0.72 1.07 1.59 2.36 3.48 4.33 0.0073 59.6 1.37 2.03 3.00 4.43 6.560.0045 18.0 0.74 0.92 1.15 1.70 2.52 0.0060 35.4 0.70 1.04 1.54 2.27 3.37 4.18 0.0060 35.4 0.81 1.19 1.77 2.61 3.87 4.81 0.0075 61.5 1.40 2.08 3.07 4.54 6.730.0050 20.4 0.82 1.02 1.28 1.89 2.80 0.0065 40.4 0.76 1.12 1.66 2.46 3.64 4.52 0.0065 40.4 0.87 1.29 1.91 2.83 4.19 5.20 0.0090 73.3 1.69 2.50 3.70 5.47 8.100.0058 24.4 0.95 1.19 1.48 2.20 3.25 0.0068 44.5 0.79 1.17 1.74 2.58 3.81 4.74 0.0068 44.5 0.91 1.35 2.00 2.97 4.39 5.45 0.0093 76.0 1.79 2.62 3.83 5.59 8.380.0062 26.6 1.01 1.27 1.59 2.35 3.48 0.0070 46.6 0.82 1.21 1.79 2.65 3.92 4.88 0.0070 46.6 0.94 1.39 2.06 3.05 4.51 5.61 0.0096 78.2 1.80 2.66 3.94 5.82 8.630.0076 33.7 1.24 1.55 1.93 2.86 4.23 0.0090 58.7 1.05 1.56 2.30 3.41 5.04 6.27 0.0090 58.7 1.21 1.79 2.65 3.92 5.80 7.21 0.0110 90.0 2.06 3.05 4.51 6.68 9.890.0090 41.0 1.47 1.84 2.30 3.41 5.04 0.0120 81.0 1.40 2.08 3.07 4.54 6.73 8.36 0.0120 81.0 1.61 2.39 3.53 5.23 7.74 9.61 0.0130 106.5 2.44 3.60 5.33 7.88 11.680.0104 48.0 1.71 2.13 2.66 3.94 5.83 0.0170 117.0 1.99 2.94 4.35 6.44 9.53 10.56 0.0170 117.0 2.29 3.38 5.00 7.40 10.96 12.14 0.0140 115.0 2.62 3.87 5.73 8.47 12.56

0.0008 2.6 0.06 0.07 0.08 0.12 0.18 0.0012 5.7 0.06 0.09 0.13 0.19 0.28 0.35 0.0012 5.7 0.07 0.10 0.15 0.22 0.32 0.40 0.0022 18.0 0.17 0.25 0.37 0.55 0.810.0009 3.2 0.06 0.08 0.10 0.14 0.21 0.0015 7.5 0.07 0.11 0.16 0.23 0.35 0.43 0.0015 7.5 0.08 0.12 0.18 0.27 0.40 0.49 0.0025 20.3 0.19 0.29 0.42 0.63 0.930.0010 3.4 0.07 0.08 0.11 0.16 0.23 0.0018 9.4 0.09 0.13 0.19 0.28 0.42 0.52 0.0018 9.4 0.10 0.15 0.22 0.32 0.48 0.60 0.0032 26.2 0.25 0.37 0.54 0.80 1.190.0020 7.5 0.14 0.17 0.21 0.31 0.46 0.0022 10.9 0.08 0.13 0.21 0.34 0.51 0.63 0.0022 10.9 0.09 0.15 0.24 0.39 0.59 0.73 0.0035 28.8 0.27 0.40 0.59 0.88 1.300.0022 8.2 0.15 0.18 0.23 0.34 0.51 0.0025 13.3 0.12 0.18 0.26 0.39 0.58 0.72 0.0025 13.3 0.14 0.21 0.30 0.45 0.66 0.83 0.0039 32.3 0.30 0.45 0.66 0.98 1.450.0025 9.7 0.17 0.21 0.26 0.39 0.58 0.0028 15.0 0.13 0.20 0.30 0.44 0.65 0.81 0.0028 15.0 0.15 0.23 0.34 0.50 0.74 0.93 0.0040 32.7 0.31 0.46 0.68 1.01 1.490.0030 11.0 0.20 0.25 0.32 0.47 0.69 0.0030 16.0 0.14 0.21 0.32 0.47 0.69 0.86 0.0030 16.0 0.17 0.25 0.36 0.54 0.80 0.99 0.0045 36.8 0.35 0.51 0.76 1.12 1.660.0032 11.9 0.21 0.27 0.34 0.50 0.74 0.0032 17.2 0.15 0.23 0.34 0.50 0.74 0.92 0.0032 17.2 0.18 0.26 0.39 0.57 0.85 1.06 0.0051 41.8 0.40 0.59 0.87 1.28 1.900.0033 12.2 0.22 0.28 0.35 0.51 0.76 0.0039 21.4 0.19 0.28 0.41 0.61 0.90 1.12 0.0039 21.4 0.22 0.32 0.47 0.70 1.04 1.29 0.0055 45.0 0.43 0.63 0.93 1.38 2.040.0035 13.9 0.27 0.32 0.37 0.55 0.81 0.0044 26.3 0.21 0.31 0.46 0.69 1.02 1.26 0.0044 26.3 0.24 0.36 0.53 0.79 1.17 1.45 0.0060 49.0 0.46 0.69 1.02 1.50 2.230.0038 16.0 0.26 0.32 0.40 0.59 0.88 0.0049 30.0 0.24 0.35 0.52 0.77 1.13 1.41 0.0049 30.0 0.27 0.40 0.60 0.88 1.30 1.62 0.0065 53.3 0.50 0.75 1.10 1.63 2.420.0040 17.3 0.27 0.34 0.42 0.63 0.92 0.0054 32.0 0.26 0.38 0.57 0.84 1.25 1.55 0.0054 32.0 0.30 0.44 0.66 0.97 1.44 1.79 0.0073 59.6 0.57 0.84 1.24 1.83 2.710.0045 18.0 0.30 0.38 0.48 0.70 1.04 0.0060 35.4 0.29 0.43 0.63 0.94 1.39 1.72 0.0060 35.4 0.33 0.49 0.73 1.08 1.60 1.98 0.0075 61.5 0.58 0.86 1.27 1.87 2.780.0050 20.4 0.34 0.42 0.53 0.78 1.16 0.0065 40.4 0.31 0.46 0.69 1.02 1.50 1.87 0.0065 40.4 0.36 0.53 0.79 1.17 1.73 2.15 0.0090 73.3 0.70 1.03 1.53 2.26 3.340.0058 24.4 0.39 0.49 0.61 0.91 1.34 0.0068 44.5 0.33 0.48 0.72 1.06 1.57 1.95 0.0068 44.5 0.38 0.56 0.83 1.22 1.81 2.25 0.0093 76.0 0.74 1.08 1.58 2.31 3.460.0062 26.6 0.42 0.52 0.65 0.97 1.43 0.0070 46.6 0.34 0.50 0.74 1.09 1.62 2.01 0.0070 46.6 0.39 0.57 0.85 1.26 1.86 2.31 0.0096 78.2 0.74 1.10 1.62 2.40 3.560.0076 33.7 0.51 0.64 0.80 1.18 1.75 0.0090 58.7 0.43 0.64 0.95 1.41 2.08 2.58 0.0090 58.7 0.50 0.74 1.09 1.62 2.39 2.97 0.0110 90.0 0.85 1.26 1.86 2.75 4.080.0090 41.0 0.61 0.76 0.95 1.41 2.08 0.0120 81.0 0.58 0.86 1.27 1.87 2.77 3.45 0.0120 81.0 0.67 0.99 1.46 2.16 3.19 3.97 0.0130 106.5 1.01 1.49 2.20 3.25 4.820.0104 48.0 0.70 0.88 1.10 1.62 2.41 0.0170 117.0 0.82 1.21 1.80 2.66 3.93 4.36 0.0170 117.0 0.94 1.40 2.06 3.05 4.52 5.01 0.0140 115.0 1.08 1.60 2.36 3.50 5.18

TRI-HELICAL CELLCHART #11

PYRAMID CELLCHART #12 QUADRANGULAR CELLCHART #13 QUADRANGULAR CHANNELED CELLCHART #14 TRI-HELICAL CELLCHART #15

QUADRANGULAR CHANNELED CELLCHART #6

5% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

35% SOLIDS

45% SOLIDVOLUME 5%

SOLIDS15%

SOLIDS25%

SOLIDS45%

SOLIDS50%

SOLIDS CELL DEPTH5% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

50% SOLIDS CELL DEPTH VOLUME15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSCELL

DEPTH VOLUME 5% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

45% SOLIDS

CELL DEPTH VOLUME 5%

SOLIDS

35% SOLIDS

45% SOLID

OFFSET GRAVURE OFFSET GRAVURE OFFSET GRAVURE OFFSET GRAVURE

VOLUME 5% SOLIDS

15% SOLIDS

25% SOLIDS

45% SOLIDS

50% SOLIDS CELL DEPTH5%

SOLIDS15%

SOLIDS25%

SOLIDS35%

SOLIDS50%

SOLIDS CELL DEPTH VOLUME15% SOLIDS

25% SOLIDS

35% SOLIDS

45% SOLIDS

CELL DEPTH VOLUME 5%

SOLIDS15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSCELL

DEPTH VOLUME 5% SOLIDS

PYRAMID CELLCHART #8 QUADRANGULAR CELLCHART #9 QUADRANGULAR CHANNELED CELLCHART #10

35% SOLIDS

45% SOLIDCELL DEPTH5%

SOLIDS15%

SOLIDS25%

SOLIDS35%

SOLIDS

DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE

VOLUME 5% SOLIDS

15% SOLIDS

25% SOLIDS

45% SOLIDS

50% SOLIDS

50% SOLIDS CELL DEPTH VOLUME15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSCELL

DEPTH VOLUME 5% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

45% SOLIDS

CELL DEPTH VOLUME 5%

SOLIDS

TRI-HELICAL CELLCHART #7

6. CHOOSE THE ROLL FROM ANY VENDOR CHART THAT MATCHES THE VOLUME AND CELL TYPE.

DIRECT FORWARD GRAVURE DIRECT FORWARD GRAVURE DIRECT FORWARD GRAVUREPYRAMID CELLCHART #4 QUADRANGULAR CELLCHART #5

2. DETERMINE TYPE OF GRAVURE COATER3. DETERMINE TYPE OF GRAVURE CELL4. FIND THE DESIRED COATWEIGHT IN THE CHART

5. TRACE THAT ROLL OVER TO THE VOLUME IN THE SAME CHART

45% SOLIDS

50% SOLIDS

NOTE: THIS IS FOR CHROME PLATED GRAVURE ROLLS ONLY !1. DETERMINE SOLIDS

50% SOLIDS NUMBER CELL DEPTH VOLUME15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSNUMBER CELL DEPTH VOLUME 5%

SOLIDS15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSNUMBER CELL DEPTH VOLUME 5%

SOLIDS

ENGRAVING COATING CHARTWEIGHT IN POUNDS DRY SOLIDS PER REAM - 432,000 SQUARE INCHES

WEIGHT OF MATERIAL 8 LBS. PER GALLON IN SOLUTION

PYRAMID CELLCHART #1 QUADRANGULAR CELLCHART #2 TRI-HELICAL CELLCHART #3

0.0012 5.7 0.22 0.32 0.48 0.71 1.05 1.310.0015 7.5 0.27 0.40 0.60 0.89 1.31 1.630.0018 9.4 0.33 0.48 0.72 1.07 1.58 1.960.0022 10.9 0.30 0.49 0.80 1.30 1.93 2.390.0025 13.3 0.46 0.68 1.00 1.48 2.19 2.720.0028 15.0 0.51 0.76 1.12 1.66 2.45 3.050.0030 16.0 0.55 0.81 1.20 1.78 2.63 3.260.0032 17.2 0.59 0.87 1.28 1.89 2.80 3.480.0039 21.4 0.71 1.05 1.56 2.31 3.42 4.240.0044 26.3 0.80 1.19 1.76 2.61 3.85 4.790.0049 30.0 0.90 1.32 1.96 2.90 4.29 5.330.0054 32.0 0.98 1.46 2.16 3.20 4.73 5.880.0060 35.4 1.10 1.62 2.40 3.55 5.26 6.530.0065 40.4 1.19 1.76 2.60 3.85 5.69 7.070.0068 44.5 1.24 1.84 2.72 4.03 5.96 7.400.0070 46.6 1.28 1.89 2.80 4.14 6.13 7.620.0090 58.7 1.64 2.43 3.60 5.33 7.88 9.790.0120 81.0 2.19 3.25 4.80 7.10 10.51 13.060.0170 117.0 3.11 4.60 6.80 10.06 14.89 16.50

50% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

45% SOLIDS

CELL DEPTH VOLUME 5%

SOLIDS

QUADRANGULAR CELL2

Gravure Applicator Design

Wiping vs. PlowingWiping vs. Plowing Location of Enclosed ApplicatorLocation of Enclosed Applicator

Open Pan vs. Open Pan vs. Enclosed Enclosed vs. vs. PressurizedPressurized

Pressurized Gravure Applicator

The ability to pressurize the PGH limits the effect of dwell andensures that the gravure cells will be filled with the coating. A standard enclosed applicator is restricted by the time the gravure cell is in the wetted chamber. Thusly, with the PGH thegravure cells will be filled at higher speeds than with a standard applicator or open pan system.

GPM Density In

Density Out

0.63 9.2 7.770.99 8.92 8.31.44 8.91 8.51.98 8.95 8.632.44 8.65 8.64

OFFSET GRAVURE

•Gravure Pattern•Rubber compound•Gravure Speed•Enclosed Applicator

Smooth Roll CoatersIncrease Speed – Lower Coat Weight

• Pan design• Splashing• Slinging• Rubber compound• Rubber hardness

SMOOTH ROLL

Rubber Hardness/CompoundRubber Hardness/Compound

Multi Chamber PanMulti Chamber Pan Sling GuardsSling Guards

Rubber Rolls Compound

BU

NA

N

BU

TYL

EPD

M

HYP

OLO

N

NA

TUR

AL

RU

BB

ER

NEO

PREN

E

SBR

SILI

CO

NE

THIO

KO

L

VIT

ON

AR

CO

THA

NE

(OSE

RIE

S)PO

LYES

TER

UR

ETH

AN

E

POLY

ETH

ERU

RET

HA

NE

Tensile Strength F F F G G-E G-E F P P F E E G-E

Hardness Range 20-100 30-75 25-90 45-85 30-100 10-95 30-100 35-90 15-80 65-80 50-95 10-95 65-95

Max Service Temperature 250 350 350 300 212 250 250 400+ 212 500+ 275 212 212

Ozone Resistance P E E E P F-G P E E E P E E

Cut Resistance F F F F-G G G F P P F E G-E+ F-E

Tear Strength F F F G G G F P-G P F G F-E G

Compression Set F-G F G F F G F E P G F F-VG G-VG+

Abrasion Resistance F F F G G-E G-E F-G P-F P F E G-E+ G-E

Heat Resistance P F F-G P E E F G-E P F P G G-ESwell Resistance to ASTM Oil #1 E P P F-G P F-G P G E E E E GSwell Resistance to ASTM Oil #3 E P P F P F P F E E E E G

Reference for Fuel B G-E P P P P F P P E E G-E E GKetones:MEK P E E F G F F-G F E P P P-E F-GAromatics:Toluene F P P P P P-F P P P-F G-E G G-E F-GAliphatics:Hexane E P P G P G P P E E E E EEsters:Ethyl Acetate P-F E E F E G F G E E P-F P-F P

Cellosolve F E E G E E F E E E P-F P-F PChlorinated Solvents:Methylene Chloride P E E P E P P F G E P P P

Trichloroethylene P P P P P P P P P E P P PGlycols:Diethylene Glycol E E E E E E G E E E E G-E G-EAlcohols:Isopropal Alcohol G-E E E E E G-E G G E E G-E E G-EWater:Distelled (75 F) G-E E E E E G G-E G G-E E G G ECaustics:10%NaOH F-E E E E E E G E G E G P FAcids:10% H2SO4 F-E E E E E F-E G F-E F-G E G P F

Animal / Vegetable Oils G G-E G G P-G G P-G E E E G E G-E

Gravure CoaterGravure Coater

Smooth Roll CoaterSmooth Roll Coater

Correct Pump Selection

• Double Diaphragm• Peristaltic• Centrifugal• Positive Displacement

Diaphragm

PeristalticUp to 4.5 gpm

Centrifugal

Positive Displacement

Plumbing•Hose Diameter•Drooping return lines•Return Lines T’d together•Trough system•Amount of return flow•Pump size•Pump design

Conclusion - ReviewGravure Coaters•Select correct gravure pattern•Pan design•Enclosed Applicator or PGH•Correct Pump•Correct Plumbing•Upgrade to Offset Gravure

Smooth Roll Coaters•Pressure Setting•Roll Speed•Pan Design•Sling Guards•Rubber Hardness•Upgrade to 3-Roll Design

Thank You

PRESENTED BY

Lee A. OstnessProduct Manager Coating & Drying SystemsBlack Clawson Converting Machineryostnessl@bc-egan.com

Please remember to turn in your evaluation sheet...